2004 GMC W5500 Forward

The 2004 GMC W5500 Forward is a heavy-duty truck that is available with either a 7.8L V8 Vortex gasoline engine or a 6.6L Duramax diesel engine. Both engines are mated to a Allison 5-speed automatic transmission. The W5500 has a maximum payload capacity of 12,000 lbs. and a maximum towing capacity of 24,500 lbs. Drivers like the W5500 for its powerful engine, durable construction, and comfortable interior. However, some owners have reported issues with the vehicle’s engine, transmission, and other components.

Engine

7.8L V8 Vortex Gasoline Engine

• Intake Manifold Gasket Failure
  • Description/Symptoms: Coolant leaks, engine overheating, rough idling
  • Solution: Replace intake manifold gasket
  • Estimated Cost to Fix: $500 - $1,000
  • Recalls: None Found
• Fuel Injector Failure
  • Description/Symptoms: Engine misfires, loss of power, increased fuel consumption
  • Solution: Replace fuel injectors
  • Estimated Cost to Fix: $300 - $600
  • Recalls: None Found

6.6L Duramax Diesel Engine

• Turbocharger Failure
  • Description/Symptoms: Loss of power, black smoke from exhaust
  • Solution: Replace turbocharger
  • Estimated Cost to Fix: $1,500 - $3,000
  • Recalls: None Found
• Fuel Injector Failure
  • Description/Symptoms: Engine misfires, loss of power, increased fuel consumption
  • Solution: Replace fuel injectors
  • Estimated Cost to Fix: $300 - $600
  • Recalls: None Found

Transmission

Allison 5-Speed Automatic Transmission

• Slipping Gears
  • Description/Symptoms: Transmission slips out of gear when driving
  • Solution: Replace transmission
  • Estimated Cost to Fix: $2,500 - $4,000
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Transmission shuddering, loss of power
  • Solution: Replace torque converter
  • Estimated Cost to Fix: $1,000 - $2,000
  • Recalls: None Found

Suspension

• Leaf Spring Failure
  • Description/Symptoms: Sagging suspension, uneven tire wear
  • Solution: Replace leaf springs
  • Estimated Cost to Fix: $500 - $1,000
  • Recalls: None Found
• Shock Absorber Failure
  • Description/Symptoms: Rough ride, poor handling
  • Solution: Replace shock absorbers
  • Estimated Cost to Fix: $200 - $400
  • Recalls: None Found

Electrical

• Battery Failure
  • Description/Symptoms: Difficulty starting vehicle, electrical system malfunctions
  • Solution: Replace battery
  • Estimated Cost to Fix: $100 - $200
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Battery not charging, electrical system malfunctions
  • Solution: Replace alternator
  • Estimated Cost to Fix: $300 - $500
  • Recalls: None Found

Exterior

• Rust
  • Description/Symptoms: Rust spots on body panels, frame, and suspension components
  • Solution: Repair or replace rusted parts
  • Estimated Cost to Fix: Varies depending on the extent of damage
  • Recalls: None Found
• Headlight Failure
  • Description/Symptoms: Headlights not working or flickering
  • Solution: Replace headlight bulbs or headlight assembly
  • Estimated Cost to Fix: $100 - $300
  • Recalls: None Found

Interior

• Climate Control Failure
  • Description/Symptoms: Climate control system not working or not blowing cold air
  • Solution: Replace climate control module or actuator
  • Estimated Cost to Fix: $300 - $600
  • Recalls: None Found
• Power Window Failure
  • Description/Symptoms: Power windows not working or moving slowly
  • Solution: Replace power window motor or switch
  • Estimated Cost to Fix: $200 - $400
  • Recalls: None Found

Summary

The 2004 GMC W5500 Forward is a powerful and durable truck, but it is not without its issues. The most common problems reported by owners are engine and transmission failures, as well as issues with the suspension, electrical system, and interior components. The severity of these issues varies, and the cost to fix them can range from a few hundred dollars to several thousand dollars. In general, the W5500 is a reliable vehicle, but it is important to be aware of the potential issues before purchasing one.